large structural panels using thermoplastic composite

Large Structural Panels Using

Thermoplastic Composite

ACMA January 2011

Who Are We

AS Composite Inc. is a privately owned Research & Development Canadian company founded in 2003.

Products ServicesSandwich Panels Continued Research & DevelopmentPlates Analysis, Prototyping & DesignMoulded Parts Process Development & Fabrication

Technology Transfer

Thanks to our innovative technology, leading edge equipment, highly qualified, and talented team, we have gained recognition as the leader in this industry

Who Are We Certification & Patents

• Process and machine for producing lightweight

thermoplastic composite products in a continuous

manner (Patented)

• Fibre reinforced thermoplastic composite panel

(Patented)

• Fibber reinforced thermoplastic composite bridge deck

(Patented)

Product• All of our products are based on Thermoplastic

reinforced with continuous fibres (composites)

Thermoplastic Advantage

• Clean Fabrication

• Better performance, in climates (-40c to 80c) • Impact resistant, 100% Non-Toxic +

Environmentally Friendly

Fibre & Matrix• Glass

• Carbon• Kevlar

• Thermoplastic

• Extremly light, non-corrosive, durable, Reusable, Weldable

What is a Sandwich Panel? A panel with plastic, metal, paper or other material enclosed between twolayers of a different material.

Generally, face plates may be fabricated with stiff materials as compared to the core that isfabricated by materials like plastics, composites etc….

A.S. Panel

Composite (Commingled yarnof polypropylene and fibreglass)used as face plates.

Core material is generally fabricated by PP Honeycomb

or Foam

Composite Material

Fiber: Glass Carbon Kevlar

Matrix: Thermoplastic Thermoset

Advantages of Thermoplastic

Clean fabrication

Reusable, reformable, weldable, flexible

Non-toxic and environmental friendly

Better performance in low & high temperature

More resistant in impact

Low cost

OUR SOLUTION?

Solution

Sandwich structure +

Using a continuous Process (sequentially heating - compacting - cooling )

=(Innovative Machine)

Solution (Cont.)

Capabilities

• Length up to 20 ft and more (7.0 m)

• Production rate: 4 ft/min (1.2m /min)

• Thickness of panels 0.25 to 4 in (6 to 100 mm)

• Core and face plates are fused (not adhered in pp

cores)

• Flexibility in forming; drums can be

altered to obtain any desired shape (not just flat)

Advantages of A.S Panel

Compared to other alternatives:• Lighter

• Easy to transport, to manipulate and to install

• Energy dissipation in impact especially at low temperature

Applications

Applications

Concrete Forming

• Easy Manipulation • Durability• Recyclable

Applications

Prefab. Housing• Light Weight• Insect Resistant• Water resistant• Rust proof• Flame retardant• Easy Assembly• Permanent Construction

Applications

Advertisement Signs• Non-adhesion to ice and snow

ApplicationsTruck Trailer

• Corrosion free • Weight reduction• Recyclable• Non toxic• High impact resistance

Applications

Guard Rail• Corrosion free • Recyclable• Easy Manipulation• High impact resistance

Applications

Bridge Deck Slab• Corrosion free• Long life span • Weight reduction

Plates & Molded Parts• Thermoplastic polymer reinforced with Fiberglas• 0.5 mm to 6 mm thick• Up to 3mm in width, Unlimited length• • Superior to competitive panels such as plywood, steel,

Aluminum, Fiberglas, etc Military Applications

• Some applications in production through our partners• Some applications tested successfully, and ready to be used• Some application under testing directly with AS Composite

• (*More information on testing available upon request due to confidentiality

Structural Performance

One floor buildings:Used for wall, roof and floor without any extrastructure and can resist harsh climateloadings (ex: abundant snow in Canada, violent wind in Mexican Gulf up to 200 km/hrs,strong seismic load)

Two floors and more:• Used as internal and external self supporting

walls

Structural Performance(cnt’d)

• Bending Strength (3 Points test, ASTM3931): 61.8 Mpa

• Compression Strength (ASTM C365):21.7 Mpa

• Impact Strength (Room temperature, appraised by a falling dart impact test with Ф20 mm spherical head > 250J/m2

• Missile Impact Test TAS 201 based on Florida

Building Code results: No penetration in exterior skin

Coating AS Panel Covering AS Panel surface by interlayer (Polyester/Glass fiber mat) during the fabrication process allows a perfect adhesion to:

• Concrete• Acrylic Latex Paint

• Plaster or other similar materials

Thermal Performance

• For 100 mm thick: Minimum R value : R20 = 0.9 m2 ºCJW

• No Thermal Bridge in walls or roof

• Thermal Stability within -29ºC to 100ºC, 97% Humidity is 2%

• Water vapor permeability < 1

Fire performance (using Fire Retardant)

Test ASTM E 84-05

Specimen: Panel:

100 mm thick (1.5 mm skin), 0.6 m x 7.3m, core: Fiber Glass/EPS fire retardant

Results:Flame spread Index (FSI) 5Smoke Developed Index (SDI) 135

Time to ignition 502 secDripping and flamming NonNo Dangerous Gas emited in fire

Fire Performance

AS panel may be used as Structural Insulated panel for internal or external walls in Multi floor building if:

Coated with fire retardant cover such as:

•Ferox 18 mils or •Firetec•Coated with chalk or concrete•Finished with chalk sheet (Dry wall)

AS Panels with these coatings meet:

•Class A of International Building Code Chapter 8 interior finish, Section 803•NFPA 5000 Chapter 10 interior finish, section 10.3•Testing based on ASTM E84-05

Partners

National Research Council Canada (NRC / IMI)

Sherbrooke University

Massachusetts Institute of Technology (M I T)

British Columbia (UBC)Industrial Material Initiative (IMI)Industrial Research Assistance Program (IRAP)

Opportunities

• Unique process and product (patent-pending)• Became a reference of this domain of activity• Creates possibilities for development of new

industrial applications• Energize technology transfer

Conclusion

Although it seems the A.S. Panels costs more compared to materials like metal and Aluminum, its lower cost for handling, assembly, transportation and maintenance makes it more competitive and efficient on the market.

Think About

Durability – Cost & Maintenance - Time

Think About